Scania DC09 Installation guide

Brand: Scania

Model: DC09

Type: Installation guide

This manual is also suitable for

01:02 Issue 10 en-GB

Installation manual

Intake system and ventilation

Industrial engines

DC09, DC13, DC16

OC16

INSTALLATION

MANUAL

01:02 Issue 10 en-GB 2

Changes from the previous issue............................................................................3

Intake air .................................................................................................................. 4

Intake air taken from outside engine room.......................................................... 5

Intake air taken from engine room ...................................................................... 8

Ventilation requirements for gas engines..............................................................9

Air cleaner..............................................................................................................10

Air cleaners with precleaner.............................................................................. 11

Air cleaners without precleaner......................................................................... 12

Crankcase ventilation............................................................................................13

Open crankcase ventilation ............................................................................... 13

Closed crankcase ventilation............................................................................. 14

Connection to turbocharger .................................................................................15

Cleanliness requirements................................................................................... 15

Charge air pipe .................................................................................................. 15

Stage IV/Tier 4f engines ................................................................................... 16

Important data.......................................................................................................20

INSTALLATION

MANUAL

Changes from the previous issue

01:02 Issue 10 en-GB 3

Changes from the previous issue

The changes made in this document compared with the previous issue are marked

with a line in the left-hand margin. The changes are also described below.

• Max. permissible vacuum in the intake system has been changed to 40 mbar for

16 litre single-speed engines. See Intake air taken from outside engine room

• Max. permissible vacuum in the engine compartment for engines without fan

(1 mbar) has been removed. 2 mbar now applies to all engines. See Intake air tak-

en from engine room.

• Safety cartridges are no longer included with air cleaners with precleaners. Safety

cartridges can instead be purchased as an option. See Air cleaner

• Clearances for Air cleaners with precleaner

and Air cleaners without precleaner

have been corrected.

• Section Important data

has been added.

INSTALLATION

MANUAL

Intake air

01:02 Issue 10 en-GB 4

Intake air

If the intake line is located close to exhaust pipes or other hot parts, radiation protec-

tion should be used to limit unnecessary heating of the intake air.

REQUIREMENT!

The intake air temperature may not exceed the ambient temperature by more than

5°C for Stage IV/Tier 4f engines, or 10°C for other engines.

Measure the temperature when the installation is complete. Refer to 01:08 Measur-

ing instructions for installation inspection.

If the intake air temperature upstream of the turbocharger continuously exceeds

30°C, then engine power may drop. If the engine is enclosed in some manner, make

sure that there is an adequate flow of intake air.

The dependence of the engine power on intake air temperature is shown in the chart

on the right. This diagram is only valid for DC engines. 100% engine power is shown

under actual test conditions at the factory.

Gas engines can be subject to significant power loss if the intake air to the turbo-

charger has a high temperature in combination with the fuel having a low MN value

(knock-sensitive fuel).

The engine air consumption in kg/min at full power and at different engine speeds is

indicated in the tables showing the air consumption and radiated heat for the relevant

engine type in 01:06 Technical data.

100

10 20 30

40 50

°C

340 422

Engine power dependence on intake air temperature. 100 % at 25°C, 1,000 mbar, en-

gine power setting not corrected.

This diagram is only valid for DC engines.

A = Engine power.

B = Intake air temperature.

INSTALLATION

MANUAL

Intake air

01:02 Issue 10 en-GB 5

Intake air taken from outside engine room

In engine systems where the engine intake air comes from outside the engine room

and is led via a fresh air line to the engine, the vacuum for the intake system should

be measured.

The air intake should be located so that the intake air is as clean as possible and so

that neither the engine exhaust gases nor heated air from the engine room can mix

with the intake air. The air intake should be designed to exclude water, snow and con-

tamination.

The intake air must not contain chemical pollutants, such as CFCs.

REQUIREMENT!

The maximum permissible vacuum in the intake system is 30 mbar. For 16 litre sin-

gle-speed engines, a vacuum of 40 mbar is permissible. This value includes the vac-

uum in the new air filter, connected coarse filter and in the fresh air line.

Measure the vacuum when the installation is complete. Refer to 01:08 Measuring in-

structions for installation inspection.

INSTALLATION

MANUAL

Intake air

01:02 Issue 10 en-GB 6

The following applies to the fresh air line:

• The fresh air line must not be routed with any sharp bends.

• The inside of the fresh air line must be flat and even.

• If a hose is used as a fresh air line, it must be rigid enough that it does not collapse

onto itself.

It is not necessary to check the vacuum in the following cases:

• If the intake system is comprised of air hoses and air pipes from Scania's standard

range.

• If the fresh air line is maximum 5 m and has an inside diameter of at least 160 mm

for DC09 or 210 mm for DC13 and DC16, respectively.

If the planned fresh air line is longer than 5 m, the required diameter must be calcu-

lated as illustrated. The vacuum upstream of the turbocharger must then be measured.

Refer to 01:08 Measuring instructions for installation inspection.

REQUIREMENT!

The total vacuum in the intake system with a blocked air filter must not exceed

65 mbar.

Engine damage will not occur up to 100 mbar, but fuel consumption and smoke will

increase. Above 100 mbar there is a risk that the air volume to the engine will be in-

adequate, resulting in breakdowns.

B (kg/min)

365 744

A (mm)

500

400

300

200

100

10 20 30 40 50 60

25 m

50 m

Calculation of minimum diameter of the intake line.

A = Intake line diameter.

B = Air consumption.

INSTALLATION

MANUAL

Intake air

01:02 Issue 10 en-GB 7

Ventilation of the engine room with fresh air line to the engine

If the intake air to the engine is taken from outside the engine room, it is important

to check that the temperature in the engine room does not get too high.

REQUIREMENT!

The temperature in the engine compartment must not exceed 90 °C.

Measure the temperature when the installation is complete. Refer to 01:08 Measur-

ing instructions for installation inspection.

If the temperature exceeds 90°C, there is a risk of malfunction in the engine electrical

components and engine control unit. If there is a risk that the temperature will exceed

this value, the engine room must be ventilated.

When dimensioning the engine room ventilation, other air consumers in the engine

room must also be considered. The amount of radiated heat emitted by the various

engines is indicated in 01:06 Technical data.

The exhaust pipes should be insulated to reduce the radiated heat in the engine room.

See 01:04 Exhaust system.

INSTALLATION

MANUAL

Intake air

01:02 Issue 10 en-GB 8

Intake air taken from engine room

When the engine intake air is taken from the engine room, the air intake must be lo-

cated in the engine room. The opening area should be large enough to ensure that no

vacuum arises in the engine room. The air intake should also be designed and posi-

tioned so that it cannot be closed or accidentally blocked by water, snow or contam-

inants.

The air intake should be located so that the intake air is as clean as possible and so

that neither the engine exhaust gases nor heated air from the engine room can mix

with the intake air to the engine.

In the chart on the right-hand side, the recommended minimum area for the air intake

can be read from the engine air consumption.

If several engines or other air consumers are located in the same engine room, the

diameter should be increased correspondingly.

REQUIREMENT!

The vacuum in the engine compartment must not exceed 2 mbar.

Measure the vacuum when the installation is complete. Refer to 01:08 Measuring in-

structions for installation inspection.

0,1 0,2 0,3 0,4

kg/min

340 420

Calculation of minimum air intake area.

INSTALLATION

MANUAL

Ventilation requirements for gas engines

01:02 Issue 10 en-GB 9

For installations where the engine draws the intake air directly from the engine room,

the engine room must normally be equipped with a ventilation system. This system

should extract the air heated by radiation etc. in order for the requirement of a low

intake air temperature to be met.

If there is a refrigerator compressor in the engine room, it is important that any leak-

age of refrigerant does not contaminate the intake air.

The radiated heat from the engine exhaust pipe downstream of the engine must also

be taken into account. The heat radiation depends on how much of the line is inside

the engine room and how much of it is insulated.

There is also additional heat due to efficiency losses in driven units located in the en-

gine room.

The amount of radiated heat emitted by the engine is indicated in the tables showing

the radiated heat for the relevant engine type in 01:06 Technical data .

Ventilation requirements for gas engines

The canopy or room where the engine and gas regulator are installed must have a

ventilation flow of at least 1 m

/second. However, normally the cooling requirement

and maximum temperature of the canopy or room require a significantly higher ven-

tilation flow. If the ventilation flow is insufficient, the electric shut-off valves for fuel

must be closed immediately.

In order to ensure the ventilation flow, Scania recommends monitoring the function-

ality of the fan. For example, this can be done with the help of monitors that check

the pressure difference across the radiator, or the pressure difference between the in-

take air entering and outlet air exiting the canopy. The electric shut-off valves for fuel

will close if a ventilation flow of less than 0.5 m

/second is detected when the engine

has started.

If the ventilation flow cannot be ensured, a gas monitor should be installed. This is

to monitor the gas content of the air and close the electric fuel shut-off valves if a

maximum of 10% of the ignition limit (4,400 ppmv) has been attained.

The coordinator must close the electric shut-off valves for fuel if the red engine warn-

ing light comes on, because it comes on if the engine control system detects a loss of

combustion air.

INSTALLATION

MANUAL

Air cleaner

01:02 Issue 10 en-GB 10

Air cleaner

The engines are delivered with air cleaners with paper filters. The air cleaner is avail-

able with or without integrated self-cleaning precleaner.

If the air cleaner has a precleaner, a safety cartridge can be purchased as an option.

This protects the engine from contamination, for example, if the main filter is dam-

aged or when renewing the main filter element. An air cleaner without precleaner is

not available with safety cartridge.

Bear in mind the following when installing the air cleaner:

• The air cleaner must be fitted so that it is easily accessible for cleaning and filter

renewal.

• The vacuum indicator must be positioned so that it can be read easily.

• In order to be able to remove the filter element, clearance in the air cleaner exten-

sion is required. Refer to the subsequent page.

• The intake line between the air cleaner and the turbocharger must be sealed so that

no unfiltered air can be drawn into the engine. The intake line must be designed

in such a way that it cannot collapse onto itself as a result of a large pressure drop.

The intake line should be able to withstand a vacuum of 200 mbar before it col-

lapses onto itself.

• The material and composition of the intake line between the air filter and turbo-

charger must be such that it cannot release rust or objects that could damage the

engine.

An effective self-cleaning prefilter is recommended for particularly dusty environ-

ments. Even engine systems exposed to driving snow can require a special type of

prefilter.

For such equipment, Scania refers to filter system specialists who can give recom-

mendations about the system which is most suitable for a particular type of engine

installation.

It is also important to make sure that any insulation in the engine room and around

the exhaust pipes cannot come loose and be drawn into the intake line.

If a non-Scania air filter is used, engine air consumption and filter element pore size

must be considered.

INSTALLATION

MANUAL

Air cleaner

01:02 Issue 10 en-GB 11

Air cleaners with precleaner

IMPORTANT!

Air cleaners with precleaners must be fitted horizontally with the drain pipe pointing

downwards.

Air filters with precleaner are available in three different sizes for DC engines: 13,

15 and 18 inches. They can be ordered with or without rain protection.

A = free space required for prefilter renewal (mm).

13 inches 900

15 inches 1,010

18 inches 1,120

165

152

397 189

INSTALLATION

MANUAL

Air cleaner

01:02 Issue 10 en-GB 12

Air cleaners without precleaner

IMPORTANT!

Air cleaners without precleaners must be fitted horizontally with the air intake (1)

pointing downwards. The air cleaner may also be fitted vertically, but only if it is fit-

ted indoors or in such a way that water cannot get into the air filter. The cover should

then face downwards.

Air filters without precleaner are available in two different sizes for DC engines: 13

inch and 15 inch.

A = free space required for prefilter renewal (mm).

13 inches 900

15 inches 1,010

165

152

397 190

INSTALLATION

MANUAL

Crankcase ventilation

01:02 Issue 10 en-GB 13

Crankcase ventilation

Open crankcase ventilation

If the engine is located in an enclosed space, crankcase gases should be led out of the

engine room. This is especially important when the engine is equipped with a driving

fan, since the crankcase gases will otherwise settle on the radiator, binding dirt and

dust, which reduces the cooling effect.

The crankcase ventilation pipe (1) has a diameter of 32 mm.

The following points are important for external ventilation of crankcase gases:

• The crankcase gases must not be led to outlet ducts for engine room ventilation or

exhaust gases.

• The crankcase ventilation lines from multiple engines must not be joined to form

a single pipe.

• The crankcase ventilation line should be made from pipe or oil-resistant hose,

connected to the ventilation pipe on the engine.

• When the crankcase ventilation line is extended in cold environments, it must be

designed to ensure that condensation cannot freeze in the hose. The extension of

a crankcase ventilation line may need to be insulated.

• When the crankcase ventilation line is extended, the extension must be designed

to ensure that no pockets are formed. It must also have a continuous downward

slope so that it can neither freeze nor can oil accumulations form resulting in too

high a pressure in the crankcase.

• Any crankcase ventilation pipe with its outlet outside the engine room must be

protected so that no water or contaminants can get into the crankcase.

• If pipe is used, there should be a flexible, oil-resistant line between the engine and

pipe to absorb the engine movements.

• If hose is used, it must be clamped so that no sharp kinks are formed.

• The crankcase ventilation pipe outlet must not be positioned where there is a risk

of it becoming blocked.

335 751

Open crankcase ventilation

A. DC09.

B. DC13.

335 753

Open crankcase ventilation, DC16

INSTALLATION

MANUAL

Crankcase ventilation

01:02 Issue 10 en-GB 14

Closed crankcase ventilation

For certain engine systems, external ventilation of crankcase gases could be exten-

sive and expensive. This applies, for example, to generator sets in large buildings

where very long evacuation pipes are required. Gas engines always have closed

crankcase ventilation.

When there are special requirements for closed crankcase ventilation, e.g. for envi-

ronmental reasons, it is permissible to allow the crankcase gases to be led to the in-

take line between the air filter and the turbocharger.

It is not permissible to lead the crankcase gases to the intake upstream of the engine

air filter.

335 754

Closed crankcase ventilation

A. DC09, DC13

B. DC16, OC16

INSTALLATION

MANUAL

Connection to turbocharger

01:02 Issue 10 en-GB 15

Connection to turbocharger

Cleanliness requirements

IMPORTANT!

Observe the utmost cleanliness when installing all parts from the air filter up to the

turbocharger. If foreign particles enter the turbocharger, this could quickly lead to

impaired performance and breakdown.

Do not remove the protection from the turbocharger inlet pipes and charge air pipe

before they are connected.

Charge air pipe

The installation of the charge air pipe recommended by Scania for DC engines is

shown in the illustration.

IMPORTANT!

Position a flexible hose as close to the turbocharger connection as possible to reduce

forces and torques.

The weight of the charge air pipe must not put any load on the turbocharger. There-

fore, support the charge air pipe downstream of the turbocharger connection with a

sturdy bracket.

337 360

Recommended installation of charge air pipe, DC engines.

1. Turbocharger

2. Flexible hose

3. Charge air pipe

4. Bracket

INSTALLATION

MANUAL

Connection to turbocharger

01:02 Issue 10 en-GB 16

Stage IV/Tier 4f engines

Inlet pipe for connection to turbocharger

The Scania inlet pipes for connection to the turbocharger must be used on all engines

certified according to Stage IV/Tier 4f. The inlet pipes are available in two different

versions for DC09 and DC13, and in one version for DC16.

Combined sensor T4000 for measuring atmospheric pressure and temperature is po-

sitioned in each version of the inlet pipe.

Tightening torque for the clamp joint connected to the turbocharger: 20 Nm. Applies

only to DC09 and DC13.

336 772

Inlet pipes for DC09 and DC13.

340 413

Inlet pipe for DC16.

INSTALLATION

MANUAL

Connection to turbocharger

01:02 Issue 10 en-GB 17

Mass flow sensor pipe

All engines certified according to Stage IV/Tier 4f are supplied with an inlet pipe

with a mass flow sensor T126. The mass flow sensor pipes are available in 2 different

versions for DC09 and DC13, and in 1 version for DC16.

The dimensions and air direction for the mass flow sensor pipes are shown in the il-

lustrations below.

Mass flow sensor pipes for DC09 and DC13

389

Ø 126

Ø 150

4x M10

336 769

271

Ø 126

190

Ø 150

2x M8

336 770

INSTALLATION

MANUAL

Connection to turbocharger

01:02 Issue 10 en-GB 18

In order to get the best possible measured value when measuring the mass flow, the

following recommendations for the installation of all types of mass flow sensor pipes

apply:

• Install the mass flow sensor pipe as near to the turbocharger as possible.

• Use pipes between the turbocharger and the mass flow sensor pipe as far as pos-

sible.

• Make pieces of hose as short as possible.

• Maximum distance between the inlet pipe and mass flow sensor pipe is 800 mm.

This applies to all combinations of inlet pipes and mass flow sensor pipes.

• Use hose which is rigid enough that it does not collapse onto itself.

• Support the mass flow sensor pipe so that the weight of the pipe is not resting on

the turbocharger.

Tightening torque for hose clamps: 5 Nm.

4xM8

340 412

Ø 150

Ø 140

220

414

Mass flow sensor pipe for DC16

Max. 800 mm

336 774

Maximum distance between the inlet pipe and mass flow sensor pipe

INSTALLATION

MANUAL

Connection to turbocharger

01:02 Issue 10 en-GB 19

• The switch of the mass flow sensor must not be on the underside of the mass flow

sensor pipe where it may come into contact with condensation and dirt. See illus-

tration.

• If a pipe bend is installed upstream of the mass flow sensor pipe, the outer radius

of the pipe bend must be on the same side as the measuring body of the mass flow

sensor ±90°. The airflow must hit the measuring body of the mass flow sensor (1).

336 873

The relationship between the pipe bend and mass flow sensor pipe if a pipe bend is

installed upstream of the mass flow sensor pipe

INSTALLATION

MANUAL

Important data

01:02 Issue 10 en-GB 20

Important data

Max. recommended temperature for engine intake air 30°C

Requirements which must be met for the fresh air line so that the vacuum does not need to be checked Length: max. 5 m

Inner diameter: at least 210 mm.

Maximum permissible vacuum in the intake system with cleaned or new filter

16 litre single-speed engines 40 mbar

Other engines 30 mbar

Maximum permissible vacuum in the intake system with blocked filter 65 mbar

Maximum temperature in the engine compartment when the intake air is taken from outside the engine compartment 90°C

Max. permissible vacuum in engine compartment (pressure difference) 2 mbar

Scania DC09 Installation guide

Brand: Scania

Model: DC09

Type: Installation guide

This manual is also suitable for

Download PDF

report

Scania DC09 Installation guide

This manual is also suitable for

Scania DC09 Installation guide

Related papers

Other documents